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Budget Bronco Buildup
Stage 2
In Stage 2 we will start working on the suspension. First will come the 3" body lift install, second we will install a 3.5" suspension lift using BC bronco Coils, National Rear Springs, and Rancho 9000 Shocks.
The suspension lift will also include a custom wristed arm to help make it twist better, and custom shock towers to allow the use of the longest possible shocks.
For More information on the Suspension tricks I will be using, check out the Suspension Modification page.
Stage Two has Started!
Because of the poor condition of the tires, I felt that replacements were in due order before the upcoming winter. I Decided that it would be most economical to purchase the tires that I wanted to use when the vehicle was completed than to buy smaller tires now, and larger ones when the lift was done. Unfortunately, 35" tall tires don't fit under a stock bronco, so something had to be done first.
I decided that it would be best to ad the body lift first as it shouldn't take too long, and with ample fender well trimming, I should be able to fit 35" tires with little problem. I found a set of plastic 3" blocks that a friend had. They were part of a ch*vy truck lift kit, but because the truck they were used on had a flat bed, they didn't use the lift for the bed. Fortunately, there are 8 mounting points on a ch*vy truck bed, and 8 points on a EB, so I was in business.
Body Lift installation
The body lift installation was much easier than I initially thought it would be. I started early Saturday morning and had the majority of it done by supper time, and that included running into town to get the correct length bolts (twice ;-).
The first thing I did for the lift was to loosen the steering column. This was easy enough, although you have to remember to loosen it on the fire wall and under the dash. Ford designed it well, as there are 2 holes in the bottom of the dash so you can easily reach the bolts with an extension. The next thing I did was take off the rear bumper. Because the I had recently installed my new cool Iron Horse bumpers, the bumper came off very easily. I also took the bolts of the radiator shroud.
Once everything was ready, I started pulling the body bolts. I started on the passenger side because there fewer complications (no brake or fuel lines to worry about). I first removed the rear bolt, it promptly broke. With a little time and heavy "persuasion" tools I was able to remove the remainder off the bolt. The second bolt that I tried to remove was the front bolt. Unfortunately it was very rusted, so because it was stubborn, and easily accessible, I cut it off with an angle grinder. Then I went for the bolt that is under the passengers seat. The previous owner had put a fiberglass patch on the floor and covered the bolt, but we were able to cut a small hole around the head to get it out. It had been replace recently, so it came out easily. Finally, the bolt that is behind the passenger seat. This is the one that made me nervous, because it really isn't accessible from the bottom like the others. Magically it came out perfect, I was amazed.
In order to lift the body, we put a piece of wood on a floor jack and put it under the passenger kick panel. This worked well, but we needed to lift a little more in the back to keep it level, so we used a handyman jack on the back. We were able to lift it easily to fit the spacers in, although it did lift the rear tire off the ground (we later realized that the parking brake cable was binding). Now, with all of the spacers in on that side, we ran into town to buy longer bolts.
Once we had put all of the bolts in (but not tightened them) we proceeded to the other side. These bolts seemed to come out a little easier, but the angle grinder was put to use again anyway :-(. When we lifted this side we had to be a little more careful, watching the fuel and break lines as we lifted, I was able to re-bend the brake lines and make them long enough, and found it wasn't necessary to replace the rear fuel filler hose. Now that I had all of the spacers in I tightened all of the bolts down.
Now I inspected everything. I had to bend the line to the tranny cooler a little cause it was awfully close to the alternator. I also had to re-drill the holes that hold the steering column on and put nuts behind them (the factory holes have nuts welded in). I had to make a mount to move the radiator shroud 3 inches lower also, but that was just made out of scrap metal laying around. I also found it necessary to loosen and twist the lower radiator hose to take a little bind out of it. The last thing that I did was disconnect the parking brake. The cables were way to tight, so I will live without them until I can get some longer ones from Wild Horses, or find a cheaper alternative.
Now that I had the truck lifted I took it for a spin around the block. I immediately felt more tippy, I attribute part of this to the crappy shocks that I have on it right now, and another part to the miserable small, bald tires.
So, on Monday I brought the Bronco to the local 4x4 parts shop, GM-Only (the place isn't as bad as the name might imply). They had a set of 35 x 12.5s sitting there that had my name all over them. I had them mounted on a set of 15x10 chrome rims I had laying around and threw them on the Bronco. It immediately looked like a whole new truck! I absolutely Love it. The better tires actually made the truck feel more stable (I attribute that to the more square tread pattern, and wider stance). I had to play with the tire pressure a little to get them to ride on the entire surface of the tire, but that didn't take much.
Here is a pic of the New and improved "INVSBL" Bronco.
As you can see, it is starting too look like a respectable truck. Notice the dirt on the center of the tires, I hadn't dropped the pressure enough yet, and with 25 pounds of air in a 3800 lb truck, it was riding on the center of the tire still, a few PSI less and everything was fine.
One other thing that I did as a result of the body lift was put in a smaller steering wheel. I never cared for the larger wheel, but with it a little harder to get into because of the additional 6" of height, and the fact that the wheel was now even a little closer to the seat due to the lift, I decided it had to go for a smaller wheel.